Dear Members,

The recently concluded NDE 2019 Conference and Exhibition at Bengaluru was a great success. The event attracted record number of technical papers for presentation. There was also a very good participation from exhibitors and industry delegates. In the last couple of years, there has been a conscious attempt by the organizing team to make ISNT conferences 'industry friendly'. The whole objective is to bridge the gap between the industries and ISNT for mutual benefits.

During inaugural ceremony of NDE 2019, ISNT Mumbai was presented with 'ISNT Pulsecho – Best Chapter Award' for the year 2019. The award was presented in recognition of the technical programmes and events the Chapter conducted for its members and industries. I take this opportunity to thank my colleagues at ISNT Mumbai, our members, industry representatives and all the sponsors & exhibitors for supporting our events in a big way. I assure you that we will continue to organize technical lectures, courses and conferences for the benefit of our members and industries in and around Mumbai.

I appeal to all the members of ISNT Mumbai to take active part in the Chapter activities. Please let us know if you wish to organize a programme or give a technical lecture on a topic that can be of interest to our members. Please feel free to write to us and share your suggestions on the programmes you want us to organize that can benefit our members and industries.

Stay Connected!!!

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MUMBAI CHAPTER

Technical Presentation and Demonstration of Proceq UT 8000 Ultrasonic FlawDetector with innovative IOT was held on 10th December 2019 at The Royal OrchidHotel , Chembur. The speaker was Mr. Chris Udell and Mr. Logesh Raj. Event wassponsored by M/s Testing and Measuring Equipments. Lecture was attended by 73participants.

ECT LEVEL II Course was conducted at NPCIL from 6 th to 11th January 2020 andExamination on 12th & 13th January 2020. Course coordinator was Mr.Arbind Kumarand faculties were Mr. Arbind Kumar & Mr. Mahesh B Jadhav. Examiner was Mr. NirajKumar. 18 candidates attended the course.

UT LEVEL II Course and Examination was conducted at NPCIL from 20th to 29th January 2020 and Examination on 30th & 31st January 2020. Course coordinator was Dr. Paritosh Nanekar and faculties were Dr. Paritosh Nanekar, Ms. Jothi Lakshmi , Arvind Bhide, Arbind Kumar and Mr. Santosh Saluneke. Examiner was Mr. Niraj Kumar.

Technical Lecture on Advancement in Phased Array Ultrasonic inspection Techniqueswas held on 31st January 2020 at The Acres Club, Chembur. Speaker was Mr. HirenDongare. Sponsored by M/s Olympus Medical System Pvt Ltd. 82 participants attendedthe lecture.

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ECT Course NPCIL

ECT Course participants

MT LEVEL II ICN Certification course was conducted at ISNT Office from 3rd to 5th February 2020. Examination was held on 10th February 2020. Course coordinator was Mr. L M Tolani and faculties were Mr. L M Tolani and Mr. Luke Pimenta. Examiner was Mr. N Sadasivan. Attended by 5 participants.

PT LEVEL II ICN Certification course was conducted at ISNT Office from 6th to 8th February 2020. Examination was held on 11th February 2020. Course coordinator was Mr. L M Tolani and faculties were Mr. L M Tolani and Mr. Luke Pimenta. Examiner was Mr. N Sadasivan. Attended by 5 participants.

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Technical Lecture & demonstration held on 29th Jan

Technical Lecture on 29th Jan

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ICN Course

ISNT Level III Certification / ASNT Level III Refresher course.

Industry Meet.

Technical Talks and NDT Awareness programs.

ISNT Mumbai can conduct certification courses at the premises of organization/company for a group of candidates. Please

write to us at info@isntmumabi.in for more details.

Mumbai Chapter was awarded the Best Chapter during NDE 2019 event in Bangaluru.

Arora Technologies (P) LimitedT: +91 22 6138 0600 | E: info@arorandt.com | W: www.arorandt.com

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Thickness Mapping Of Boiler Tubes With EMAT

High Temperature Thickness Gauging With EMAT

Remote Visual Inspection/Boroscopy

Tube Testing Solutions (ECT/RFT/NFT/MFL/ECA)

Corrosion Under Insulation By PECT

Phased Array Ultrasonic Testing (PAUT)

Advance NDT Services

EDDY CURRENT TESTING - Inside OutM.B.Jadhav NPCIL QA - mbjrgk@gmail.com

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INTRODUCTION: This is a continuation to the previous, very informative, discussion on the pitfalls to be avoided during Eddy Current Testing (ECT). We will go a step further in understanding one nagging question that sometimes comes to the mind of NDE Inspector preforming ECT of tubes of New Heat exchanger . Why , several indications appear in the NEW tubes , when the Tube Mill ECT report indicates - All tubes as acceptable. The same NDE Technique, ECT, is used at both places- Tube Mill & Heat Exchanger Tube Examination. Some probable reasons to this discrepency are :(1) ECT methodology, (2) Reference defect Standard and Acceptance Criteria (3) Signal representation and Analysis techniqus used & (4) Disposition of Indications - Result reporting.

TUBE MILL ECT (ECT DURING MANUFACTURE OF TUBES):ECT for tube testing begins at the manufacturer of tubes. The tube Mills Have test setup of Outside Diameter (OD) coil / Encircling Coil ECT . This is a relatively fast inspection which runs at the speed of the Tube production and the OD coil is usually mounted at a suitable location on final manufacturing stage of the production line where the tube moves through the OD coil at high speeds.. This ECT is done for detecting tube manufacturing related phenomenon viz. Scratches, Laminations, inclusions, Break marks. OD Dents. All such phenomenons are reliably detected using Single Frequency ECT. is simple and consists of usually o Reference defect standard a through hole fsay, mm an sometimes OD and es around depth (as per 0.8 diameter d ID Notch of 10% relevant Specification), These are sufficient in providing requisite sensitivity for detecting a large majority of manufacturing related defects. The ECT technique is AMPLITUDE based where the Rejection criteria is set to trigger on smallest of the reference defect signals generated Thus the ECT is a GO / NO-GO type of test. (See Fig ->) There may be INTERMEDIATE Level signals , Signals Below Reject Threshold (See Fig ->) due to tube Inside Diameter (ID) related phenomena like pilgering noise, ID Depressions/ Pits, Magnetic anomalies etc. The OD Coil has lower sensitivity to ID Phenomena . Such signals are like noise signals and have potential to mask relevant defect indications during service. Hence, tube specification should include the requirement of Signal to Noise ratio of at least 3 or higher. There is no requirement to RECORD / REPORT Intermediate amplitude signals , if any, observed during manufacturing of tubes. Moreover, the tubes having such INTERMEDIATE Signals are, usually, not considered as rejectable if the signals do not cross the Reject Threshold. Hence ,such tubes are ACCEPTABLE. The OD ECT does not, normally, call for investigating such Acceptable Indications. Thus the Tube ECT Report has no mention of such indications .Such Un-Recorded, Un-Reported ECT signals crop Up during the subsequent ECT Inspection when the tube gets installed in the Heat Exchanger and undergoes ID ECT. Such indications observed during manufacturing are mostly due to INACTIVE flaws. Those with less possibility of growing in service. (mostly… may not be always true!)

INSTALLED HEAT EXCHANGER (HX) TUBES ECT : The ECT of HX Tubes is done from the tube ID (Inside Diameter) Using an ID probe/ Bobbin probe. The ID probe method is capable of catching almost all types of Indications ID or OD. It obviously, has higher sensitivity for ID related Phenomena.

The analysis of heat exchanger tube ECT signals is based on PHASE Discrimination. This provides a clear distinction between ID and OD defects and additionally multiple frequencies can also used to further help in signal analysis. The Reference defect standard is more detailed having additional Reference defects ranging from thro Hole, OD wall thinning of 20% ,40%, 60% & 80% as well as ID Groove. The signal due to Hole when set to 40 degree, will cause all OD defect signals to appear at an angle of more than 40 deg and all ID defects will appear at an angle less than 40 degrees upto 0 degree (See Figs Below). Dents will appear at 180 degrees. A Calibration curve is drawn to obtain intermediate values of wall thinning , other than Ref defect signals The ID probe is more sensitive to ID related indications where OD coil had lower sensitivity. Hence a Tube cleared by Tube Mill ECT as ACCEPTABLE now may show additional indications . These , as mentioned above may be related to ID phenomena like pilgering noise, ID Depressions/ Pits, Magnetic anomalies etc. A clear distinction of ID related signals is indicated by phase in the range of 0 degree to 40 degree. These are usually recorded as BASELINE Indications to have distinction from In Service indications , during the service life of the HX. The ACCEPTANCE Criteria for ID ECT is normally - 40% (or more) OD wall thinning being considered as un acceptable. The Phase Analysis technique is used to determine this wall thinning The Tubes showing Indications of 40% (OD)wall thinning or more are normally plugged to avoid a potential leak during plant operation. A majority of flaws generated during Service and are ACTIVE Flaws (Those that have a probability of growing in Service). It is a common practice in Hx ECT to maintain a record of ECT indications detected and to monitor them at regular intervals to establish their growth trend. The aim of ID ECT is to avoid a tube leak in service, also to avoid unnecessary plugging of tubes thus maximize the service life of the HX. Hence, it becomes necessary to separate the manufacturing related indications from the service related mostly Active-Growing indications. A baseline data of the initial manufacturing related ECT indications is thus useful. A clear distinction between Inactive and Active Flaws is desirable.

CONCLUSION: To summarise the combined effect of OD and ID ECT in achieving Flaw less tubes:: Ÿ Develop manufacturing specifications with capability of producing tubes that are

having no Indicatios. (Ideal thought!) Ÿ Alternately , use BOTH OD and ID ECT at Manufacturers works, with appropriate

acceptance criteria, to weed out Tubes with any indications: ID or OD.Ÿ Use baseline inspections to identify Manufacturing related Flaws.Ÿ Adopt a periodic inspection program to Identify Active , In Service Flaws and monitor

them to avoid Potential leaks during Plant operation.Ÿ Adjust the Tube plugging criteria to avoid unnecessary plugging of Inactive flaws at

the same time , not missing the Active ones! Thus Prolonging the Life of Heat Exchangers .

(Gratefully acknowledge the numerous online resources on NDT and ECT for the information available which was immensely useful in compiling this article)

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DENT

HOLE

80% OD FB HOLE

60% OD FB HOLE

40% OD FB HOLE

20% OD FB HOLE

30 DEG APART

10% OD GROOVE

10% ID GROOVE

CAL TUBE

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11” x 8.5”

5” x 7.5”

5” x 3.7”

1.6” x 3”

8,000

4,000

2,000

1,000

1440

720

360

180

9,440

4,720

2,360

1,180

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EC TEAM